Concrete Experts - please help?

8 years ago

OK, the next challenge in my quest to build my dream house is to figure out how to remedy the mason's screw-up on our concrete patio. Not here to complain or vent, but really just seeking advice. I'm hoping there are some "concrete experts" out here who can weigh in and give some ideas on how to best deal with this bad situation we're in....

Our huge concrete patio was poured on Nov 1 and saw cut the next day. Before cutting they ran a machine to smoothen the concrete surface. This is the size of the patio (measuring 18' deep by 60' wide; red lines were where they saw cut the expansion joints -- or is it control joints -- I can never tell the difference between the two)...

Anyway, when I went back to look at the results, I was absolutely horrified. I expected clean and straight lines but what we got was this instead:

I've seen enough youtube videos and houzz pics to know that some chipping is to expected, but the chips on this job was all over. The bigger issue is that the lines aren't even cut straight -- some are so squiggly they look like a drunk person operated the saw.

The same saw cut results (not quite as bad) appears in the garage as well (done by the same mason), but with the patio, I'm a lot more upset because the patio is where we have the outdoor kitchen and gas fire pit; it will be where we entertain guests.

I did a quick calc, a concrete patio this size (5" thick) is roughly 65,000 lbs. Clearly, the logistics, time, cost, and RISKS involved in ripping it out for a do-over is phenomenal. While the contractor has said they will be willing to re-do it, I am worried about vibration damage (from jackhammer) and flying debris -- access to this patio is through a 33' wide 10' tall lift-and-slide doors from Germany with triple pane glass ($$$$$) -- last thing I want is for these to be mis-aligned and or damaged.

What are our options?

Thanks.

Featured Answer

PRO

GN Builders L.L.C

8 years ago

Looks like they cut it by hand using concrete saw without a guide. this is not the way to do this.

The reason why you have chipped edges, etc, is because concrete needs to be cut within 6-12 hours after finishing. You also need walk behind saw to cut long straight lines or set up straight edge guides.

If you cutting in fresh concrete BT has the video, the only thing is when you have a 60' run you have to cut it.

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Comments (9)

PRO
Virgil Carter Fine Art
8 years ago
Plywood or OSB over all windows and siding before jack hammering and removal. Is the contractor paying for removal and reinstallation, as he should?

Before the next round, ask the contractor if the boys who will do the work have ever done similar satisfactory work before? No reason for the results on your job.
BT
8 years ago
I prefer thrower joints https://www.youtube.com/watch?v=MWxqyZ0ATwY

This looks pretty bad sorry.
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Germain Wong
Original Author
8 years ago
Thanks GN Builders. Actually, they cut it using a huge machine (not a hand tool). Also, the cuts were made around 8am, the morning AFTER the pour (the pour was done early afternoon the day before).

I don't understand how the result can be so bad.... it looks like what's happened is that the concrete raveled? I thought that only happens if the saw cuts were made TOO soon?
PRO
GN Builders L.L.C
8 years ago
The only way this could happen if they didn't pay attention or didn't know what they were doing. It looks like the saw came out of the cut and messed up the slab, maybe there was an issue with the blade, etc.

If they will jackhammer the slab, you don't have to worry about the vibration. Like Virgil said they should cover everything to prevent damage. If someone was using temper near new foundation, they can cause damage to the foundation from the vibration.

Good luck
just_janni
8 years ago
last modified: 8 years ago
Are you going to dye and finish the concrete with multi color process? Would you consider that? If you did - it would minimize the wavy saw cuts and chips. Alternatively - you could have them FILL the saw cuts with caulk and then get a nice epoxy floor coating or other material (quartz aggregate, etc). Likely cheaper and safer than ripping it out, disposing of it, and redoing.... The latter would be my recommendation. There are a ton of nice finishes for concrete that can cover that mess.
worthy
8 years ago
last modified: 8 years ago
I've had garage floors done a week later freehand with a concrete saw that were nearly perfect. Re-do. It's a slab easily picked up with a Bobcat.

Nice to see a contractor recognizing and correcting his error!
Sammy
8 years ago
I think I’d want my new patio poured in 8’ x 10’ sections.
geoffrey_b
8 years ago
SWI - sawing while intoxicated.

I agree with Sammy - have it poured in small sections - and have them 'throw' the joints while it's still wet. I don't like the look of sawed joints - even it they are straight.